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<p>Fluid catalytic cracking (FCC) devices in petrochemical industries and refractories experience challenges in locating commercial items that possess well-suited thermo-mechanical characteristics for operating at temperatures below (&lt; 900&#xa0;°C). Since colloidal silica-bonded refractories often begin to densify at temperatures above 1200&#xa0;°C, applying sintering additives to accelerate these densification processes is a highly interesting technical approach. This study aims to assess the performance of high alumina refractory castables that incorporate a sintering additive based on magnesium borate, as well as colloidal silica binder sources. This study examined the consequences of including magnesium borate as a boron source to high alumina colloidal silica-bonded castable sintered at temperatures as high as 1200&#xa0;°C. Measurements of apparent porosity, cold modulus, and hot modulus of rupture evaluated the compositions. XRD and SEM investigations have identified the reaction processes and phase evolution relevant to the high temperatures. Incorporating 1.5 wt% of the sintering additive into the castable significantly enhanced the hot modulus of rupture (39.5&#xa0;MPa) and cold modulus of rupture (43.2&#xa0;MPa) following fire at 815&#xa0;°C for 5&#xa0;h. An enhanced refractory was also produced by combining nano-bonded silica with magnesium borate as a sintering additive. This combination exhibited a transient liquid formation at a higher temperature, leading to high mechanical strength at 815&#xa0;°C and 1200&#xa0;°C.</p>

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Magnesium borate containing high alumina nano-bonded refractory castable for the petrochemical industry

  • 期刊论文

  • 发表日期：

    2025年12月23日

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  • Manish Kumar,
  • Durgesh Rai,
  • Manas Ranjan Majhi

摘要

Fluid catalytic cracking (FCC) devices in petrochemical industries and refractories experience challenges in locating commercial items that possess well-suited thermo-mechanical characteristics for operating at temperatures below (< 900 °C). Since colloidal silica-bonded refractories often begin to densify at temperatures above 1200 °C, applying sintering additives to accelerate these densification processes is a highly interesting technical approach. This study aims to assess the performance of high alumina refractory castables that incorporate a sintering additive based on magnesium borate, as well as colloidal silica binder sources. This study examined the consequences of including magnesium borate as a boron source to high alumina colloidal silica-bonded castable sintered at temperatures as high as 1200 °C. Measurements of apparent porosity, cold modulus, and hot modulus of rupture evaluated the compositions. XRD and SEM investigations have identified the reaction processes and phase evolution relevant to the high temperatures. Incorporating 1.5 wt% of the sintering additive into the castable significantly enhanced the hot modulus of rupture (39.5 MPa) and cold modulus of rupture (43.2 MPa) following fire at 815 °C for 5 h. An enhanced refractory was also produced by combining nano-bonded silica with magnesium borate as a sintering additive. This combination exhibited a transient liquid formation at a higher temperature, leading to high mechanical strength at 815 °C and 1200 °C.